Conext MPPT Solar Charge Controller ( )

Transcription

1 Conext MPPT Solar Charge Controller ( ) Installation and Owner s Guide Revision H November 2017 Owner s Manual

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3 Conext MPPT Solar Charge Controller Installation and Owner s Guide

4 Copyright and Contact Copyright Schneider Electric. All Rights Reserved. All trademarks are owned by Schneider Electric Industries SAS or its affiliated companies. Exclusion for Documentation UNLESS SPECIFICALLY AGREED TO IN WRITING, SELLER (A) MAKES NO WARRANTY AS TO THE ACCURACY, SUFFICIENCY OR SUITABILITY OF ANY TECHNICAL OR OTHER INFORMATION PROVIDED IN ITS MANUALS OR OTHER DOCUMENTATION; (B) ASSUMES NO RESPONSIBILITY OR LIABILITY FOR LOSSES, DAMAGES, COSTS OR EXPENSES, WHETHER SPECIAL, DIRECT, INDIRECT, CONSEQUENTIAL OR INCIDENTAL, WHICH MIGHT ARISE OUT OF THE USE OF SUCH INFORMATION. THE USE OF ANY SUCH INFORMATION WILL BE ENTIRELY AT THE USER S RISK; AND (C) REMINDS YOU THAT IF THIS MANUAL IS IN ANY LANGUAGE OTHER THAN ENGLISH, ALTHOUGH STEPS HAVE BEEN TAKEN TO MAINTAIN THE ACCURACY OF THE TRANSLATION, THE ACCURACY CANNOT BE GUARANTEED. APPROVED CONTENT IS CONTAINED WITH THE ENGLISH LANGUAGE VERSION WHICH IS POSTED AT Document Number: Revision: Revision H Date: November 2017 Product Part Number: Contact Information Please contact your local Schneider Electric Sales Representative or visit our website at: Information About Your System As soon as you open your product, record the following information and be sure to keep your proof of purchase. Serial Number Product Number Purchased From Purchase Date

5 About This Guide Purpose Scope Audience Organization The purpose of this Guide is to provide explanations and procedures for installing, configuring, operating, and troubleshooting the Conext MPPT Solar Charge Controller (solar charge controller). This Guide provides safety guidelines, detailed planning and setup information, procedures for installing the unit, as well as information about operating and troubleshooting the unit. It does not provide details about particular brands of photovoltaic (PV) panels. You need to consult individual PV manufacturers for this information. This Guide does not provide sufficient information for anyone but a qualified installer to install this product. Installers should be electricians or technicians fully educated on the hazards of installing electrical equipment. The monitoring and operation information in this manual is intended for anyone who needs to operate the solar charge controller. This Guide is organized into five chapters and four appendices. Chapter 1 describes features and functions of the Conext MPPT Solar Charge Controller. Chapter 2 contains information and procedures to install the Conext MPPT Solar Charge Controller. Chapter 3 contains information and procedures to configure the Conext MPPT Solar Charge Controller. Chapter 4 contains information about the operation of the Conext MPPT Solar Charge Controller. Chapter 5 contains information about identifying and resolving possible problems with systems using a Conext MPPT Solar Charge Controller. Appendix A provides the specifications for the Conext MPPT Solar Charge Controller. Appendix B is a guide to the Conext System Control Panel monitoring and configuration menus for the Conext Solar Charge Controller. Appendix C provides information on boost charging for flooded lead-acid batteries in off-grid applications Revision H iii

6 About This Guide Abbreviations and Acronyms AFCI CEC CSA DC FCC GFP I MP I SC LCD LED MPP MPPT MSDS NFPA PDP PV SCP STC UL VAC VDC V MP V OC Arc Fault Circuit Interrupter Canadian Electric Code Canadian Standards Association Direct Current Federal Communications Commission Ground Fault Protection Current at maximum power per STC Short circuit current rating of an PV panel under STC Liquid Crystal Display Light Emitting Diode Maximum Power Point Maximum Power Point Tracking Material Safety Data Sheet National Fire Protection Association Conext Power Distribution Panel Photovoltaic System Control Panel Standard Test Conditions specific to photovoltaic panels (1000 W/m 2, light spectrum AM 1.5 and 25 C); panel nameplate ratings are based on STC and may be exceeded under other conditions. Underwriters Laboratories Volts AC Volts DC Voltage at maximum power per STC Open circuit voltage rating of a PV panel under STC Related Information For more information about Schneider Electric as well as its products and services, visit iv Revision H

7 Important Safety Instructions READ AND SAVE THESE INSTRUCTIONS - DO NOT DISCARD This guide contains important safety instructions for the Conext MPPT Solar Charge Controller that must be followed during installation procedures. Read and keep this Installation and Owner s Guide for future reference. Read these instructions carefully and look at the equipment to become familiar with the device before trying to install, operate, service or maintain it. The following special messages may appear throughout this bulletin or on the equipment to warn of potential hazards or to call attention to information that clarifies or simplifies a procedure. The addition of either symbol to a Danger or Warning safety label indicates that an electrical hazard exists which will result in personal injury if the instructions are not followed. This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. DANGER DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. WARNING WARNING indicates a potentially hazardous situation which, if not avoided, can result in death or serious injury. CAUTION CAUTION indicates a potentially hazardous condition which, if not avoided, can result in minor or moderate injury. NOTICE NOTICE indicates important information that indicates a potentially hazardous situation, which, if not avoided, can result in equipment damage Revision H v

8 Safety Safety Information 1. Before installing or using this device, read all instructions and cautionary markings located in (or on) this guide, the unit, the batteries, PV array, and any other equipment used. 2. All electrical work must be done in accordance with local, national, and/or international electrical codes. 3. This product is designed for indoor mounting only. Do not expose this unit to rain, snow or liquids of any type. 4. To reduce the chance of short-circuits, use insulated tools when installing or working with the unit or any DC source (such as PV, hydro, wind, or batteries). 5. Remove all jewelry when installing or working with the unit or any DC source. This will greatly reduce the chance of accidental exposure to live circuits. 6. The unit contains more than one live circuit (batteries and PV array). Power may be present at more than one source. 7. This product contains no user-serviceable parts. DANGER HAZARD OF ELECTRICAL SHOCK, EXPLOSION, OR ARC FLASH Apply appropriate personal protective equipment (PPE) and follow safe electrical work practices. See NFPA 70E or CSA Z462. This equipment must only be installed and serviced by qualified electrical personnel. Never operate energized with covers removed Energized from multiple sources. Before removing covers identify all sources, de-energize, lock-out, and tag-out and wait 2 minutes for circuits to discharge. Always use a properly rated voltage sensing device to confirm all circuits are de-energized. Failure to follow these instructions will result in death or serious injury. DANGER HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH Disconnect positive and negative PV conductors before servicing. PV conductors are to be treated as Hazardous Live and must be disconnected. Normally GROUNDED conductors may be UNGROUNDED and ENERGIZED when a GROUND FAULT is indicated on the front panel. Must be serviced by qualified personnel. Failure to follow these instructions will result in death or serious injury. vi Revision H

9 Safety LIMITATION ON USE WARNING The Conext MPPT Solar Charge Controller is not intended for use in connection with life support systems or other medical equipment or devices. Failure to follow these instructions can result in death or serious injury. CAUTION BURN HAZARD Do not touch the solar charge controller s heatsink during operation or before servicing immediately after ceasing operation. Failure to follow these instructions can result in injury. NOTICE LIGHTNING PROTECTION To protect the solar charge controller s insulation and conductors from damage due to a sudden over-voltage surge such as a lightning strike, install a DC-rated lightning arrestor on the DC input line. Failure to follow these instructions can damage the equipment. Battery Safety Information BATTERY HAZARD WARNING A battery can produce the following hazards to personal safety: electrical shock burn from high-short-circuit current fire or explosion from vented gasses when using Lithium Ion batteries, ensure that the battery pack being used includes a certified Battery Management System (BMS) with safety protocols Observe proper precautions when working with or around batteries. Failure to follow these instructions can result in death or serious injury. Always wear eye protection when working with batteries Revision H vii

10 Safety Remove all jewelry before working with batteries. Wear rubber gloves and boots when handling batteries. Never work alone. Have someone assist you with the installation or be close enough to come to your aid when working with batteries. Always use proper lifting techniques when handling batteries. Always use identical types of batteries. Never install old or untested batteries. Check each battery s date code or label to ensure age and type. Batteries should be installed in a well-vented area to prevent the possible buildup of explosive gasses. If the batteries are installed inside an enclosure, vent its highest point to the outdoors. When installing batteries, allow at least 1 inch of air space between batteries to promote cooling and ventilation. NEVER smoke in the vicinity of a battery or generator. Always connect the batteries first, then connect the cables to the inverter or controller. This will greatly reduce the chance of spark in the vicinity of the batteries. Use insulated tools when working with batteries. When connecting batteries, always verify proper voltage and polarity. Do not short-circuit battery cables. Fire or explosion can occur. Do not open or damage the batteries. Exposure to electrolyte is harmful to eyes and skin. It is toxic. In the event of exposure to battery electrolyte, wash the area with soap and water. If acid enters the eyes, flood them with running cold water for at least 15 minutes and get immediate medical attention. Do not dispose of batteries in a fire. Always recycle old batteries. Contact your local recycling center for proper disposal information. Determine if the battery is inadvertently grounded and if so, remove the source from ground. Contact with any part of a grounded battery can result in electrical shock. Remove these grounds during installation and maintenance. viii Revision H

11 Safety FCC Information to the User This equipment has been tested and found to comply with the limits for a Class B digital device, pursuant to part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a residential environment. This equipment generates, uses and can radiate radio frequency energy and, if not installed and used in accordance with the instruction guide, may cause harmful interference to radio communications. However, there is no guarantee that interference will not occur in a particular installation. If this equipment does cause harmful interference to radio or television reception, which can be determined by turning the equipment off and on, the user is encouraged to try to correct the interference by one or more of the following measures: Reorient or relocate the receiving antenna. Increase the separation between the equipment and the receiver. Connect the equipment to a different circuit from that to which the receiver is connected. Consult the dealer or an experienced radio/tv technician for help. CAUTION Unauthorized changes or modifications to the equipment could void the user s authority to operate the equipment Revision H ix

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13 Contents Important Safety Instructions v 1 Introduction Features Maximum Power Point Tracking Charge Controlling Three-Stage Battery Charging Bulk Stage Absorption Stage Float Stage Two-Stage Battery Charging No Float Stage Battery Temperature Compensation Equalization Charging Auxiliary Output Functions Load Control Vent Fan Alarms Automatic PV Array Night Disconnect Installation Materials List and Tool Requirements PV Array Requirements MPPT Voltage Range Mounting Choosing a Location Removing the Wiring Compartment Cover Removing Knockouts Mounting the Charge Controller Grounding Internal Ground Fault Protection Disabling Ground Fault Protection for Negative Grounded and Ungrounded Arrays Installing a Positive-Grounded Battery System Disabling the Charge Controller s Internal PVGFP Circuit PV Connection and Auxiliary Lines Wiring DC Terminal Connector Locations Wire Size and Over-Current Protection Requirements Current Rating Minimum Wire Gauge xi

14 Contents Over-current Protection Long-distance Wire Runs Maximum One-way Distance and Wire Size Connecting the Charge Controller Connecting Multiple Units Aux Output Connections Disconnecting the Charge Controller Network Installation Network Components Network Layout Connecting Network Cable Between Multiple Units Installing the Battery Temperature Sensor Commissioning Conext Config Tool Configuration Screens Commissioning a Single Unit Without a System Control Panel Commissioning Multiple Units Without a System Control Panel Commissioning Units Using a System Control Panel Configuration Configuring the Charge Controller Configuration Menus Basic and Advanced Menus Configuring Battery Characteristics and Battery Charging Setting a Custom Battery Type Battery Temperature Compensation Configuring Charge Controller Input Configuring the Auxiliary Output Trigger Source Descriptions Trigger Source Configurable Ranges Configuring the LCD Device Menu Resetting to Factory Defaults Operation Viewing Operating Status LCD Screens and What They Mean Normal Operation Charge Stages Dynamic Text Monitoring Charge Controller Operation Viewing Active Faults and Warnings Viewing Logged System Data Daily Logs xii

15 Contents Monthly Logs Battery Equalization Remote Power Off (RPO) Troubleshooting PV Charge Control Troubleshooting Replacing the Ground Fault Protection Fuse A B C Specifications Electrical Specifications A 2 Default Battery Charging Settings A 2 Mechanical Specifications A 3 Output Power Versus Ambient Temperature A 3 Optional Accessories A 4 Regulatory Approvals A 4 Conext System Control Panel Menus Using the SCP B 2 SCP Menu Map B 3 Changing Settings Using the SCP B 5 Viewing the Select Device Menu B 5 Viewing the solar charge controller Setup Menu B 5 Charge Controller Setup Menu B 6 Configuration Settings B 7 Monitoring the Charge Controller B 10 Charge Controller Home Screen B 10 Meters B 11 Boost Charging Using Boost Charging C xiii

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17 1 Introduction Chapter 1 describes features and functions of the Conext MPPT Solar Charge Controller. It includes: Features Maximum Power Point Tracking Charge Controlling Auxiliary Output Functions Automatic PV Array Night Disconnect Revision H 1 1

18 Introduction Features The Conext MPPT Solar Charge Controller (solar charge controller) is a photovoltaic (PV) charge controller that tracks the maximum power point of a PV array to deliver the maximum available current for charging batteries. The solar charge controller can be used with 12-, 24-, 36-, 48-, and 60-volt DC battery systems. The solar charge controller is designed to regulate PV source, but will also work with other DC sources. To be used, the DC source must meet the specifications listed on page A 2. The solar charge controller can be installed (in single or multi-unit configurations) with a Conext XW+ inverter/charger or as a stand-alone installation. Figure 1-1 Conext MPPT Solar Charge Controller Standard features of the solar charge controller include: Two- or three-stage charging process, with manual equalization to maximize system performance and maintain expected battery life. True dynamic Maximum Power Point Tracking (MPPT) to deliver the maximum available power from a PV array to a bank of batteries. See Maximum Power Point Tracking on page 1 3. Integrated PV Ground Fault Protection (PV-GFP). Convection cooled (no internal fan) using aluminum die-cast chassis and heat sink. 60-amp capacity. Configurable auxiliary output. See Auxiliary Output Functions on page Two-line, 16-character liquid crystal display (LCD) with four buttons for configuration and system monitoring. Input over-voltage and under-voltage protection, output over-current protection, and backfeed (reverse current) protection. Warning and Fault messages appear on the LCD when the unit shuts down as a protective measure Revision H

19 Maximum Power Point Tracking Over-temperature protection and power derating when output power and ambient temperature are high. Battery Temperature Sensor (BTS) to provide automatically temperaturecompensated battery charging. If the BTS is lost or damaged, a replacement can be ordered from Schneider (part number ). Xanbus communications network. Xanbus is a network communications system developed by the manufacturer which allows the solar charge controller to communicate settings and activity to other Xanbus-enabled devices. Five-year limited warranty. Maximum Power Point Tracking Maximum Power Point Tracking enables the solar charge controller to harvest the maximum energy available from the PV array and deliver it to the batteries. The MPPT algorithm continuously adjusts the array operating voltage so that the array continuously operates at its maximum power point. The solar charge controller applies a variable charging load on the array shown by the power curve (solid line) in Figure 1-2 until it finds the maximum wattage (the point at which both operating voltage and current can be maximized at the same time), as indicated by MPP in Figure 1-2. The solar charge controller then holds the array at this point for as long as the array continues to produce the maximum power possible. As panel shading, cloud cover, and sunlight angle shift, the solar charge controller finds the new maximum power point without interrupting its output power flow Current (I) Amps I sc Imp Watts MPP V mp 70 80V oc 90 Voltage (V) Volts Figure 1-2 Maximum Power Point Curve Revision H 1 3

20 Introduction Charge Controlling The solar charge controller can regulate PV array current for charging batteries at 12, 24, 36, 48, and 60 volts. It produces 60 amps of charging current and up to 3500 W (on 60-volt batteries) of charging power Figure 1-3 PV Charge Controller The solar charge controller controls how the batteries are charged by the DC source (the PV array). It can be configured to use a two-stage ( No Float ) or three-stage charging process. When charging, the solar charge controller regulates the charging voltage and current based on the amount of DC power available from the PV array and the current state of charge of the battery. The solar charge controller is able to charge a lower nominal-voltage battery from a higher-nominal voltage array. For example, the solar charge controller can charge a 12-volt battery from a 36-volt array. This gives flexibility to installers to use longer wiring runs without compromising the efficiency of a higher-voltage array. The solar charge controller is not able to charge a higher-voltage battery from a lower-voltage array. Table 1-1 Battery to PV Array Voltages Battery System Voltage Minimum PV Array Voltage Maximum PV Array Voltage (Operating) Minimum PV Array Voltage (Open Circuit) 12V 15V 24V a 27V 36V 39V 140V 150V 48V a 54V 60V 66V a.most common battery system voltage in PV and inverter systems Revision H

21 Charge Controlling Three-Stage Battery Charging Bulk Stage The three-stage charging process results in more efficient charging compared to on-off relay type or constant voltage solid-state regulators. The final float stage reduces battery gassing, minimizes electrolyte loss, and ensures complete battery recharging. Battery voltage and current vary during the three-stage charging process as shown in Figure 1-4. During the bulk stage, the solar charge controller operates in constant current mode, delivering maximum current to the batteries. When the battery voltage reaches the Absorption voltage setting, the controller automatically transitions to the absorption stage. Absorption Stage Float Stage During the absorption stage, the solar charge controller operates in Constant Voltage mode and the current falls gradually as charge is returned to the battery. The voltage limit used for the first 60 minutes of this stage is the Bulk Voltage setting. The voltage limit used for the remaining time in this stage is the Absorption Voltage setting. By default, the charge controller uses the same Bulk and Absorption voltage setting for all battery types. The default voltage limit settings (Bulk and Absorption) can be adjusted if the battery type is set to Custom. For flooded lead acid batteries only, a custom charging scheme can be used which sets the Bulk voltage higher than the Absorption voltage. The result of this is a boost voltage charge level, which has been found to be beneficial for ensuring effective charging of the battery bank for off-grid installations. For detailed information on how Boost charging works and when it is recommended, please refer to Appendix C, Boost Charging. The solar charge controller transitions to the float stage if either one of two conditions are met: 1. The charge current allowed by the batteries falls below the exit current threshold, which is equal to 2% of the programmed battery capacity (for a 500 amp-hour battery bank, this would be 10 amps), for one minute. 2. The solar charge controller has been in absorption for the programmed maximum absorption time limit. The default is 3 hours, but the time limit is programmable from 1 minute to 8 hours. During the float stage, the voltage of the battery is held at the float voltage setting. Full current can be provided to the loads connected to the battery during the float stage from the PV array. When battery voltage drops below the ReCharge Volts setting for 1 minute, a new bulk cycle will be triggered Revision H 1 5

22 Introduction Voltage Bulk State Bulk/Boost Voltage Absorption State Absorption Voltage Float State Float Voltage Recharge Voltage Boost Timer 1hr fixed Max Absorb Time - dflt 3 hrs (adjustable 1 min - 8 hrs ) Time Current Max Current Limit Absorption Exit Current Threshold = 2% of programmed AH capacity Time Figure 1-4 Three-stage Battery Charging Cycle a a.an actual charging cycle for a PV-based system that is in use while it is being charged will likely differ from the cycle represented in Figure 1-4. This is because a PV system s output is limited by the amount of solar energy available, and also because DC loads will affect the charge current and the measured battery voltage Revision H

23 Charge Controlling Note: This note is applicable to Figure 1-4 and Figure When the charge cycle is interrupted, the charger will restart charging at the beginning of the multi-stage algorithm. 2. Exit Current Threshold can be effectively disabled by programming the amp hour capacity to zero. In this case, Absorption will only exit once the Max Absorption timer expires. 3. Charge current during Equalize state (optional state not shown here) is normally limited to 10% of the programmed amp hour capacity setting. If this setting is programmed to zero Ah, the charge current during equalize is instead limited to whatever is programmed for the max current limit of the unit (default is 60A). 4. Synchronized charge states are active when more than one charging device (MPPT or Inv/Chgr) is connected in the system via the Xanbus network. i. The first unit to enter Bulk, causes all other chargers to enter Bulk. ii. The first unit to enter Absorption, causes all other units to enter Absorption. iii. The last unit that is ready to exit Absorption, triggers all units to exit Absorption and enter Float Two-Stage Battery Charging No Float Stage The two-stage charging process includes the bulk and absorption stages, but uses a No Float stage instead of Float. The relationship between charging current and battery voltage during the two-stage charging process is shown in Figure 1-5. During the No Float stage the solar charge controller does not produce any charge current. Instead the solar charge controller monitors the battery voltage and transitions back to the bulk stage once the voltage drops below the ReCharge Volts setting for one minute. Note: For more information about battery charging settings, see Table 3-2 and Table Revision H 1 7

24 Introduction Voltage Bulk State Bulk/Boost Voltage Absorption State Absorption Voltage No Float State Float Voltage Recharge Voltage Boost Timer 1hr fixed Max Absorb Time - dflt 3 hrs (adjustable 1 min - 8 hrs ) Time Current Max Current Limit Absorption Exit Current Threshold = 2% of programmed AH capacity Time Figure 1-5 Two-stage Battery Charging Cycle Revision H

25 Charge Controlling Battery Temperature Compensation The Battery Temperature Sensor (BTS) automatically adjusts the charging process of the solar charge controller. With the BTS installed, the solar charge controller increases or decreases the battery charging voltage depending on the temperature of the battery to optimize the charge to the battery and to protect it from over-charge or damage. Using the BTS can extend battery life and improve overall charging. The BTS plugs into the BTS jack located inside the wiring compartment of the solar charge controller. The BTS can be installed on the negative battery post or on the side of the battery. Equalization Charging Figure 1-6 Battery Temperature Sensor If the BTS is not installed, the voltage settings for charging are based on one of three temperature settings (Cold, Warm, or Hot) available on the solar charge controller configuration menu. See Configuring Battery Characteristics and Battery Charging on page 3 5. If there are multiple charge controllers and Conext XW+ inverter/chargers connected to the Xanbus network, then one BTS is required per battery bank. All networked Xanbus devices share battery temperature information. If there is more than one BTS is used within the system, then the highest reported temperature will be used for the temperature compensation value of the battery charge algorithm. The solar charge controller can be used to provide the battery bank with an equalize charge. Equalization is a deliberate overcharge designed to return each cell in the battery to optimum condition by reducing sulfation and stratification in the battery. The equalization charge is generally performed only on flooded, vented (non-sealed or wet ) lead-acid batteries, as recommended by the battery manufacturer. To avoid damaging your batteries, be sure to read all cautions and warnings concerning equalization charging. For more information, see Battery Equalization on page Important: The solar charge controller maximum output voltage is limited to 72 volts for a 60-volt battery system, which is the bulk voltage setting for 60-volt batteries. Because of this output limit, the solar charge controller does not equalize 60-volt batteries Revision H 1 9

26 Introduction Auxiliary Output Functions The solar charge controller has a configurable auxiliary output (producing 5 to 13 volts at up to 200 milliamps) to drive a relay for load control or to turn on devices such as vent fans or indicator alarms. The auxiliary output can be configured to perform only one function at a time. See Configuring the Auxiliary Output on page 3 13 for information about auxiliary output trigger sources and how to enable and configure the auxiliary output for your application. EQUIPMENT DAMAGE NOTICE Do not connect a high amperage device to the auxiliary output. The auxiliary output is intended only to energize a low-current circuit such as a relay coil. Connecting to a high-amperage device will open the fuse in the common line and possibly damage the unit. Failure to follow these instructions may damage the equipment. Load Control Vent Fan Alarms The solar charge controller auxiliary output can be configured to drive a relay to disconnect or reconnect loads depending on battery voltage. This load control function enables the solar charge controller to help prevent damage to the battery due to over-discharge during periods of poor charging (due to ambient temperature, for example) or excessive loads. The solar charge controller auxiliary output can be configured to power a small DC fan to clear a battery compartment of harmful gases. The solar charge controller auxiliary output must be configured to activate when the batteries reach their gassing voltage. The auxiliary output can be configured to trigger an alarm or indicator light when a pre-set condition occurs, such as low or high battery voltage, high PV array voltage, or a solar charge controller fault Revision H

27 Automatic PV Array Night Disconnect Automatic PV Array Night Disconnect At night, or when the PV array voltage is less than the battery voltage, the solar charge controller opens an internal relay to prevent battery current from flowing back to the PV array. In this mode of operation the solar charge controller draws minimal power from the battery. This automatic night-time disconnect eliminates the need for a blocking diode between the battery and the PV array. If the PV array consists of thin-film or amorphous solar modules, diodes may still be required to prevent damage during times of partial shading of the array. Check the documentation provided with the PV modules Revision H 1 11

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29 2 Installation Chapter 2 contains information and procedures to install the Conext MPPT Solar Charge Controller. It includes: Materials List and Tool Requirements PV Array Requirements Mounting Grounding Wiring Installing the Battery Temperature Sensor Commissioning Before installing the solar charge controller, read this entire chapter. Depending on your installation, you may need to perform certain installation stages in a different order than the order presented in this chapter Revision H 2 1

30 Installation Materials List and Tool Requirements The following materials are shipped with the charge controller: One Conext MPPT Solar Charge Controller One Conext Solar Charge Controller Owner s Manual One CE Conformity Declaration One Battery Temperature Sensor (BTS) One network terminator The following tools are required for installation: Phillips head screwdriver Wire cutters and wire strippers PV Array Requirements Note: The following information provides only general guidelines. The installation and rated performance of your PV array is subject to inspection and approval by the authority having jurisdiction. Each Conext MPPT Solar Charge Controller (solar charge controller) must be connected to its own PV array. Although the solar charge controller can harvest a maximum of 3500 W, the PV array size can be as high as 6720 W (based on 48 A 140 V oc = 6720 W). EQUIPMENT DAMAGE NOTICE Do not allow the PV array voltage to exceed 150 V oc (open circuit voltage) under any conditions. The array I sc (short circuit current) must not exceed the 60 A input current rating of the solar charge controller at any time. Failure to follow these instructions may damage the equipment. MPPT Voltage Range Panels rated up to 48 A at 25 C (77 F) are recommended to allow for increases in I sc caused by irradiance enhancement under certain conditions (reflection from snow, for example). The solar charge controller maximum power point tracking algorithm maximizes the energy drawn from a PV array as long as the array operating voltage is within the MPPT operational window. Charging begins when the input voltage is greater than the battery voltage. Ensure that the PV array used in the system operates within the MPPT operational window Revision H

31 Mounting Effects of array voltages outside of the MPPT operational window are shown in Table 2-1. Table 2-1 MPPT Operational Window Voltage V oc < V batt (system battery voltage) V MPP < V batt V MPP = V batt to 120 VDC 120 VDC < V MPP < 140 VDC V MPP > 140 VDC (or V oc > 140 VDC) Effect of Array Voltage Charge controller does operate. Harvest of solar energy less than optimal. Maximum harvest of solar energy. Charge controller reduces the charging current to protect the unit from voltage spikes. Charge controller shuts down. Unit may be damaged if V oc > 150 V. Charge Controller Mode Low Light Charging Charging (MPPT window) Input voltage derating Over-voltage fault Mounting The instructions in this chapter are applicable to a typical stand-alone installation. Installation procedures will vary according to your specific application. For special applications, consult a qualified electrician. If installing the solar charge controller as part of an XW+ system, see the Network Installation on page 2 25 for more information. Important: Installations must be compliant with all local electrical codes. Installation of this equipment should only be performed by a qualified electrician or by a Certified Renewable Energy (RE) System installer. Choosing a Location WARNING HAZARD OF ELECTRIC SHOCK, BURN, FIRE, AND EXPLOSION RISK OF EQUIPMENT DAMAGE The solar charge controller must be mounted vertically and installed indoors in a dry, protected location away from flammable materials, sources of high temperature, moisture, and vibration. The location must also be sheltered from direct sunlight, dust, and wind-blown debris. Failure to follow these instructions can result in death or serious injury Revision H 2 3

32 Installation Flammable or combustible materials are defined as any material containing wood, compressed paper, cellulose, plant fibers, plastics, liquids, or other material that will ignite and burn, whether flame-proofed or not according to the NFPA. Flammable liquids are defined as any liquid whose flash point does not exceed 100 F (38 C). Examples of flammable liquids are gasoline, methanol, and ether. When choosing a wall to install the solar charge controller, choose a wall that is not considered a flammable material such as concrete, brick, or metal. EQUIPMENT DAMAGE NOTICE Never install the solar charge controller where it is exposed to salt water spray. Exposure to salt water will void the warranty and may cause a shock hazard. Failure to follow these instructions can cause damage to the solar charge controller. Sealed Compartments WARNING FIRE, EXPLOSION, AND CORROSION HAZARDS To reduce the risk of fire or explosion, do not install the solar charge controller in sealed compartments containing batteries or in locations that require ignition-protected equipment. To reduce the risk of corrosion from hydrogen-sulfide gas vented by batteries, do not install the solar charge controller in sealed compartments containing batteries. Failure to follow these instructions can result in death or serious injury. If using sealed batteries, the solar charge controller can be mounted in the same enclosure as long as it is adequately ventilated. For optimal and safe operation, ensure there is adequate clearance around the solar charge controller. See Table 2-2 and Figure 2-1. If clearances are reduced below these minimums, rated performance may not be achieved Revision H

33 Mounting Table 2-2 Minimum Clearance Requirements Location Minimum Clearance Above 6 inches (150 mm). When units are mounted in a vertical stack, the topmost unit must maintain the minimum clearance to the nearest surface. In front On sides Note: Minimum clearances can be ignored when mounting two units on the side of the Conext Power Distribution Panel (PDP). For more information, see the Conext XW+ Inverter/Charger Installation Guide. Other installations must follow the guidelines in this Guide. Sufficient room to allow for easy access to read the display, to prevent accidental contact with the heat sink, and to perform maintenance. 6 inches (150 mm) on at least one side of the overall assembly. A maximum of two units can be mounted side by side or side mounted against a PDP. In both configurations, the minimum clearance around the outermost unit must be maintained. 6 inches (150 mm) on top and side(s) Figure 2-1 Minimum Clearance Requirements Removing the Wiring Compartment Cover Before mounting, remove the wiring compartment cover to access the mounting holes and the wiring terminals. The wiring compartment cover is secured with two Phillips # ½-inch (63.5 mm) screws on the front cover of the unit. See Figure Revision H 2 5

34 Installation Remove screws to access the wiring terminals. Figure 2-2 Removing the Wiring Compartment Cover Removing Knockouts Six dual and two single knockouts are provided for routing battery, PV array, BTS, and network cables into the solar charge controller. Use bushings or conduits to protect the wiring from damage from rough edges around the knockout holes. When removing knockouts, ensure that no metal shavings or fragments fall into the wiring compartment. Important: Do not drill, cut, or punch holes in the solar charge controller. Use only the knockouts provided for conduit entry Revision H

35 Mounting Keyhole slot for wall mounting 73 (2 7/8) 280 (11) 323 (12 3/4) 368 (14 1/2) Additional mounting holes Ø 6.35 (1/4) 60 (2 3/8) 53 (2 1/16) 138 (5 7/16) 26.5 (1) 14 (9/16) 118 (4 5/8) 146 (5 3/4) All measurements in mm (in.) Figure 2-3 Dimensions and Knockout Locations Single knockouts are intended for BTS and network cables DUAL KNOCKOUT (1 3/16) & (1 1/16) 2 PL DUAL KNOCKOUT (1 3/16) & (1 1/16) 2 PL KNOCKOUT (1 1/16) KNOCKOUT (1 1/16) (1 ¼) 25.9 (1) (1) DUAL KNOCKOUT (1 3/16) & (1 1/16) (1) (¾) (2) (2) 25.0 (1) (2) (2) All measurements in mm (in.) Figure 2-4 Knockout Dimensions Revision H 2 7

36 Installation Mounting the Charge Controller The solar charge controller is vertically mounted using three #10 ½-inch or #12 ½-inch (12.5 mm) pan-head screws. To mount the solar charge controller: 1. Remove the wiring compartment cover. 2. Mark the location of the keyhole slot on the wall. 3. Secure the top mounting screw in the location marked. Leave the screw head backed out approximately ¼ inch (6 mm). 4. Place the controller onto the screw and pull it down into the keyhole slot. 5. Insert two screws in the two mounting holes provided to secure the unit to the wall. 6. Provide strain-relief clamps or conduit to prevent damage to the circuit board and terminal block from pulling on the wires. ¼" (6 mm) Place keyhole slot over the mounting screw. Secure with two more screws. Figure 2-5 Mounting the Conext MPPT Solar Charge Controller Revision H

37 Grounding Grounding Internal Ground Fault Protection The charge controller can be configured to be compatible with negativegrounded and ungrounded PV systems. For information about routing the ground connection, see Figure The maximum size of the ground conductor is #6 AWG (16 mm 2 ). This wire gauge is determined by electrical code requirements regarding conduit knockout sizes, wire bending radius, and space available within the solar charge controller wiring compartment. For ground conductor requirements for your specific installation, consult your local electrical code. The solar charge controller has a PV ground fault protection (PV-GFP) fuse (600 V, 1 A) and a PV negative-ground jumper located inside the wiring compartment. These provide a negative ground bond and ground-fault protection for negative grounded PV array systems common in North American installations. ELECTRIC SHOCK HAZARD WARNING If a ground fault is indicated, normally grounded conductors and battery terminals may be ungrounded and energized. Disconnect all sources of DC power and wait at least 4 minutes for the internal circuitry to discharge before servicing the unit. Failure to follow these instructions can result in death or serious injury. FIRE HAZARD WARNING Fuses must only be replaced by qualified service personnel, such as a certified electrician or technician. For continued protection against risk of fire, replace the fuse with Littelfuse KLKD 1 or equivalent.. If PV-GFP is enabled, do not ground either PV negative or battery negative circuits. Grounding these circuits will defeat the internal PV-GFP protective function. See Figure 2-10 on page 2 20 for recommended battery circuit wiring. Failure to follow these instructions can result in death or serious injury. Important: Only one Charge Controller is to have the PV-GFP fuse installed in installations with multiple parallel solar charge controllers. Before mounting and connecting the solar charge controllers, remove the PV-GFP fuse from each unit except one Revision H 2 9

38 Installation EQUIPMENT DAMAGE NOTICE The factory default configuration of the solar charge controller will ground the PV array negative to the chassis ground through the internal PV-GFP fuse. Disable the PV-GFP circuit for ungrounded PV arrays. Failure to follow these instructions can damage the equipment. Ground fault protection fuse (behind wiring terminals) This symbol identifies the protective conductor (grounding) connection. Chassis ground terminals (2) Figure 2-6 Charge Controller Safety Ground Connector Disabling Ground Fault Protection for Negative Grounded and Ungrounded Arrays ELECTRICAL SHOCK HAZARD WARNING Disconnect PV and battery circuits before accessing the Charge Controller wiring compartment. Failure to follow these instructions can result in death or serious injury. To install the solar charge controller in a system where an external battery negative-ground bond is required, or where a positive grounded battery, or where the PV array must not be grounded, the solar charge controller internal PV- GFP circuit and ground bond must be disabled. To disable the unit s PV-GFP circuit and ground bond, move the jumper connector located on the circuit board within the wiring compartment and remove the 1A ground fault protection fuse. See Figure 2-7. Disabling the PV-GFP circuit in this way opens the negative-to-ground bond within the unit. This provides the option of using an external PV-GFP circuit, operating the Charge Controller with an ungrounded PV array, or grounding the negative circuit of the battery elsewhere in the system Revision H